Additively manufactured protrusions

Abstract

A computing component is described. The computing component includes a cosmetic prefabricated sheet of material. In some embodiments, the cosmetic prefabricated sheet of material may have a cosmetic surface and a protrusion surface. The computing component includes a protrusion extending from the protrusion surface of the cosmetic prefabricated sheet of material. In some embodiments, the cosmetic surface of the cosmetic prefabricated sheet of material is uniform in appearance to the naked eye. In some embodiments, the protrusion may have a base and an end. The base may have a cross-sectional width and the end may have a cross-sectional width. A difference in the cross-sectional width of the base and the cross-sectional width of the end may be less than 250 microns.

What is claimed is: 
     
       1. A computing component, comprising:
 a cosmetic prefabricated sheet of material having a cosmetic surface and a protrusion surface; and 
 a protrusion formed on the protrusion surface of the cosmetic prefabricated sheet of material by Selective Laser Melting (SLM) to form a plurality of layers including an innermost layer of the protrusion and an outermost layer of the protrusion, and wherein a difference in the cross-sectional width across a height of the protrusion is less than 250 microns. 
 
     
     
       2. The computing component of  claim 1 , wherein the protrusion and the cosmetic prefabricated sheet of material exhibit a microstructural bond. 
     
     
       3. The computing component of  claim 1 , wherein the cosmetic surface does not exhibit recrystallization. 
     
     
       4. The computing component of  claim 1 , wherein an area of the cosmetic surface beneath the protrusion and an area of the cosmetic surface adjacent the protrusion have the same microstructural texture. 
     
     
       5. The computing component of  claim 1 , wherein the cosmetic surface has an average surface roughness of less than 2 μm Ra. 
     
     
       6. The computing component of  claim 1 , wherein the cosmetic prefabricated sheet of material has a thickness less than 2 mm. 
     
     
       7. The computing component of  claim 6 , wherein the protrusion and the cosmetic prefabricated sheet of material form a heat affected zone that does not extend through the sheet to the cosmetic surface. 
     
     
       8. The computing component of  claim 7 , wherein a distance between the heat affected zone and the cosmetic surface is greater than 20 μm. 
     
     
       9. The computing component of  claim 8 , wherein the protrusion comprises a Faraday shield. 
     
     
       10. The computing component of  claim 1 , wherein the cosmetic prefabricated sheet of material is flat to within 100 microns over a 10 cm by 10 cm area. 
     
     
       11. The computing component of  claim 1 , wherein the protrusion includes a three-dimensional contour. 
     
     
       12. A computing component, comprising:
 a cosmetic prefabricated sheet of material; and 
 a protrusion formed on a protrusion surface of the cosmetic prefabricated sheet of material by Selective Laser Melting (SLM) to form a plurality of layers including an innermost layer of the protrusion and an outermost layer of the protrusion, the protrusion having a base and an end, the base having a cross-sectional width and the end having a cross-sectional width, a difference in the cross-sectional width of the base and the cross-sectional width of the end being less than 250 microns. 
 
     
     
       13. The computing component of  claim 12 , wherein the protrusion has a height from the base to the end of greater than 600 microns. 
     
     
       14. The computing component of  claim 12 , wherein the protrusion forms an L-shape with an orthogonal corner as viewed from above the protrusion surface. 
     
     
       15. The computing component of  claim 12 , wherein the protrusion forms a boss. 
     
     
       16. The computing component of  claim 15 , wherein the protrusion includes a support protrusion that forms a straight section connected to the protrusion that forms the boss. 
     
     
       17. The computing component of  claim 12 , wherein the cosmetic prefabricated sheet of material has a yield stress of greater than 500 MPa. 
     
     
       18. The computing component of  claim 12 , wherein the cosmetic prefabricated sheet of material has a hardness of greater than 50 Rockwell Hardness B. 
     
     
       19. The computing component of  claim 12 , wherein the cosmetic prefabricated sheet of material is cold worked. 
     
     
       20. A computing device, comprising:
 a cosmetic prefabricated sheet of material having a cosmetic surface and a protrusion surface; 
 an electronic component connected to the cosmetic prefabricated sheet of material; and 
 a protrusion extending from the protrusion surface of the cosmetic prefabricated sheet of material, the protrusion having a base and an end, the base having a cross-sectional width and the end having a cross-sectional width, a difference in the cross-sectional width of the base and the cross-sectional width of the end being less than 250 microns, wherein the protrusion shields an electronic component. 
 
     
     
       21. The computing device of  claim 20 , wherein the protrusion grounds the electronic component to the cosmetic prefabricated sheet of material.